D1370 R RADIATION CURABLE SECONDARY COATING FOR OPTICAL FIBER

Abstract

A Radiation Curable Secondary Coating comprising A) a Secondary Coating Oligomer Blend, which is mixed with B) a first diluent; C) a second diluent; D) an antioxidant; E) a first photoinitiator; F) a second photoinitiator; and G) optionally a slip additive or a blend of slip additives; wherein said Secondary Coating Oligomer Blend comprises: α) an Alpha Oligomer, which is non-urethane; β) a Beta Oligomer; which is a urethane or non-urethane. γ) a Gamma Oligomer; wherein said Gamma Oligomer is an epoxy diacrylate.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to co-pending U.S. Provisional Patent Application No. 60/874,720, “R Radiation Curable Secondary Coating For Optical Fiber”, filed Dec. 14, 2006, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to radiation curable coatings for use as a Secondary Coating for optical fibers, optical fibers coated with said coatings and methods for the preparation of coated optical fibers.

Optical fibers are typically coated with two or more radiation curable coatings. These coatings are typically applied to the optical fiber in liquid form, and then exposed to radiation to effect curing. The type of radiation that may be used to cure the coatings should be that which is capable of initiating the polymerization of one or more radiation curable components of such coatings. Radiation suitable for curing such coatings is well known, and includes ultraviolet light (hereinafter “UV”) and electron beam (“EB”). The preferred type of radiation for curing coatings used in the preparation of coated optical fiber is UV.

The coating which directly contacts the optical fiber is called the Primary Coating, and the coating that covers the Primary Coating is called the Secondary Coating. It is known in the art of radiation curable coatings for optical fibers that Primary Coatings are advantageously softer than Secondary Coatings. One advantage flowing from this arrangement is enhanced resistance to microbends.

Microbends are sharp but microscopic curvatures in an optical fiber involving local axial displacements of a few micrometers and spatial wavelengths of a few millimeters. Microbends can be induced by thermal stresses and/or mechanical lateral forces. When present, microbends attenuate the signal transmission capability of the coated optical fiber. Attenuation is the undesirable reduction of signal carried by the optical fiber. The relatively soft Primary Coating provides resistance to microbending of the optical fiber, thereby minimizing signal attenuation. The relatively harder Secondary Coating provides resistance to handling forces such as those encountered when the coated fiber is ribboned and/or cabled.

Published PCT Patent Application WO 2205/026228 A1, published Sep. 17, 2004, “Curable Liquid Resin Composition”, with named inventors Sugimoto, Kamo, Shigemoto, Komiya and Steeman describes and claims a curable liquid resin composition comprising: (A) a urethane (meth)acrylate having a structure originating from a polyol and a number average molecular weight of 800 g/mol or more, but less than 6000 g/mol, and (B) a urethane (meth)acrylate having a structure originating from a polyol and a number average molecular weight of 6000 g/mol or more, but less than 20,000 g/mol, wherein the total amount of the component (A) and component (B) is 20-95 wt % of the curable liquid resin composition and the content of the component (B) is 0.1-30 wt % of the total of the component (A) and component (B).

Many materials have been suggested for use as the polymer backbone for the urethane oligomer. For example, polyols such as hydrocarbon polyols, polyether polyols, polycarbonate polyols and polyester polyols have been used in urethane oligomers. Polyester polyols are particularly attractive because of their commercial availability, oxidative stability and versatility to tailor the characteristics of the coating by tailoring the backbone. The use of polyester polyols as the backbone polymer in a urethane acrylate oligomer is described, for example, in U.S. Pat. Nos. 5,146,531, 6,023,547, 6,584,263, 6,707,977, 6,775,451 and 6,862,392, as well as European Patent 539 030 A.

Concern over the cost, use and handling of urethane precursors has lead to the use of urethane-free oligomers in coating compositions. For example, urethane-free polyester acrylate oligomers have been used in radiation-curable coating compositions for optical glass fibers. Japanese Patent 57-092552 (Nitto Electric) discloses an optical glass fiber coating material comprising a polyester di(meth)acrylate where the polyester backbone has an average molecular weight of 300 or more. German Patent Application 04 12 68 60 A1 (Bayer) discloses a matrix material for a three-fiber ribbon consisting of a polyester acrylate oligomer, 2-(N-butyl-carbamyl)ethylacrylate as reactive diluent and 2-hydroxy-2-methyl-1-phenyl-propan-1-one as photoinitiator. Japanese Patent Application No. 10-243227 (Publication No. 2000-072821) discloses a liquid curable resin composition comprising a polyester acrylate oligomer which consists of a polyether diol end-capped with two diacids or anhydrides and terminated with hydroxy ethyl acrylate. U.S. Pat. No. 6,714,712 B2 discloses a radiation curable coating composition comprising a polyester and/or alkyd (meth)acrylate oligomer comprising a polyacid residue or an anhydride thereof, optionally a reactive diluent, and optionally a photoinitiator. Also, Mark D. Soucek and Aaron H. Johnson disclose the use of hexahydrophthalic acid for hydrolytic resistance in “New Intramolecular Effect Observed for Polyesters: An Anomeric Effect,” JCT Research, Vol. 1, No. 2, p. 111 (April 2004).

Despite the efforts of the prior art to develop coating compositions comprising urethane-free oligomers, there remains a need for Secondary Coatings which are economical while satisfying the many diverse requirements desired, such as improved curing and enhanced cure speeds, and versatility in application while still achieving the desired physical characteristics of the various coatings employed.

While a number of Secondary Coatings are currently available, it is desirable to provide novel Secondary Coatings which have improved manufacturing and/or performance properties relative to existing coatings.

SUMMARY OF THE INVENTION

The first aspect of the instant claimed invention is a Radiation Curable Secondary Coating composition, wherein said composition comprises

• • A) a Secondary Coating Oligomer Blend, which is mixed with
  • B) a first diluent;
  • C) a second diluent;
  • D) an antioxidant;
  • E) a first photoinitiator;
  • F) a second photoinitiator; and
  • G) optionally a slip additive or a blend of slip additives;

wherein said Secondary Coating Oligomer Blend comprises:

• • α) an Alpha Oligomer;
  • β) a Beta Oligomer;
  • γ) a Gamma Oligomer;

wherein said Alpha Oligomer is synthesized by the reaction of

• • α1) an anhydride with
  • α2) a hydroxyl group containing acrylate;

and the reaction product of α1) and α2) is then reacted further with

• • α3) an epoxy; in the presence of
  • α4) a first catalyst;
  • α5) a second catalyst; and
  • α6) an polymerization inhibitor;

to yield the Alpha Oligomer;

wherein said Beta Oligomer is synthesized by the reaction of

• • β1) a hydroxyl group containing acrylate;
  • β2) a diisocyanate; and
  • β3) a polyether polyol; in the presence of
  • β4) a catalyst;

wherein said catalyst is selected from the group consisting of copper naphthenate, cobalt naphthenate, zinc naphthenate, triethylamine, triethylenediamine, 2-methyltriethyleneamine, dibutyl tin dilaurate; metal carboxylates, including, but not limited to: organobismuth catalysts such as bismuth neodecanoate, CAS 34364-26-6; zinc neodecanoate, CAS 27253-29-8; zirconium neodecanoate, CAS 39049-04-2; and zinc 2-ethylhexanoate, CAS 136-53-8; sulfonic acids, including but not limited to dodecylbenzene sulfonic acid, CAS 27176-87-0; and methane sulfonic acid, CAS 75-75-2; amino or organo-base catalysts, including, but not limited to: 1,2-dimethylimidazole, CAS 1739-84-0; and diazabicyclo[2.2.2]octane, CAS 280-57-9; and triphenyl phosphine; alkoxides of zirconium and titanium, including, but not limited to zirconium butoxide, (tetrabutyl zirconate) CAS 1071-76-7; and titanium butoxide, (tetrabutyl titanate) CAS 5593-70-4; and ionic liquid phosphonium, imidazolium, and pyridinium salts, such as, but not limited to, trihexyl(tetradecyl)phosphonium hexafluorophosphate, CAS No. 374683-44-0; 1-butyl-3-methylimidazolium acetate, CAS No. 284049-75-8; and N-butyl-4-methylpyridinium chloride, CAS No. 125652-55-3; and tetradecyl(trihexyl)phosphonium; and

wherein said Gamma Oligomer is an epoxy diacrylate.

The second aspect of the instant claimed invention is a process for coating an optical fiber, the process comprising:

a) operating a glass drawing tower to produce a glass optical fiber; and

b) coating said glass optical fiber with a radiation curable Primary Coating composition;

c) optionally contacting said radiation curable Primary Coating composition with radiation to cure the coating;

d) coating said glass optical fiber with the radiation curable Secondary Coating composition of Claim 1;

e) contacting said radiation curable Secondary Coating composition with radiation to cure the coating;

The third aspect of the instant claimed invention is a wire coated with a first and second layer, wherein the first layer is a cured radiation curable Primary Coating that is in contact with the outer surface of the wire and the second layer is a cured radiation curable Secondary Coating of Claim 1 in contact with the outer surface of the Primary Coating,

• • wherein the cured Secondary Coating on the wire has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:
  • A) a % RAU of from about 80% to about 98%;
  • B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and
  • C) a Tube Tg, of from about 50° C. to about 80° C.

The fourth aspect of the instant claimed invention is an optical fiber coated with a first and second layer, wherein the first layer is a cured radiation curable Primary Coating that is in contact with the outer surface of the optical fiber and the second layer is a cured radiation curable Secondary Coating of the instant claimed invention in contact with the outer surface of the Primary Coating,

wherein the cured Secondary Coating on the optical fiber has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:

• • A) a % RAU of from about 80% to about 98%;
  • B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and
  • C) a Tube Tg, of from about 50° C. to about 80° C.

DETAILED DESCRIPTION OF THE INVENTION

Throughout this patent application the following abbreviations have the indicated meanings:

Abbreviation  Meaning
BHT           2,6-di-tert-butyl-4-methylphenol, available
              from Fitz Chem.
CAS           Means Chemical Abstracts Registry Number
CN-120Z       Epoxy diacrylate, available from Sartomer.
DABCO         1,4-diazabicyclo[2.2.2]octane, available
              from Air Products.
DBTDL         dibutyl tin dilaurate, available from OMG
              Americas.
HEA           hydroxyethyl acrylate, available from BASF
HHPA          hexahydrophthalic anhydride, available from
              Milliken Chemical.
Irgacure 184  1-hydroxycyclohexyl phenyl ketone, available
              from Ciba Geigy
Irganox 1035  thiodiethylene bis (3,5-di-tert-butyl-4-
              hydroxyhydrocinnamate), available from Ciba
              Geigy.
SR-506        isobornyl Acrylate, available as from Sartomer.
Photomer 4066 ethoxylated nonylphenol acrylate, available
              from Cognis.
Pluracol 1010 polypropylene glycol (MW = 1000), available
              from BASF;
SR-306HP      tripropylene glycol diacrylate (TPGDA), available
              from Sartomer.
SR-349        ethoxylated bisphenol A diacrylate, available
              from Sartomer.
TDI           An 80/20 blend of the 2,4- and 2,6- isomer of
              toluene diisocyanate, available from BASF
IPDI          Isophorone diisocyanate, available from Bayer
TPO           2,4,6-trimethylbenzoyldiphenylphosphine oxide
              type photoinitiator, available from Chitech.

The instant claimed invention is a Radiation Curable Secondary Coating composition, wherein said composition comprises

• • A) a Secondary Coating Oligomer Blend, which is mixed with
  • B) a first diluent;
  • C) a second diluent;
  • D) an antioxidant;
  • E) a first photoinitiator;
  • F) a second photoinitiator; and
  • G) optionally a slip additive or a blend of slip additives;

wherein said Secondary Coating Oligomer Blend comprises:

• • α) an Alpha Oligomer;
  • β) a Beta Oligomer;
  • γ) a Gamma Oligomer;

wherein said Alpha Oligomer is synthesized by the reaction of

• • α1) an anhydride with
  • α2) a hydroxyl group containing acrylate;

and the reaction product of α1) and α2) is then reacted further with

• • α3) an epoxy; in the presence of
  • α4) a first catalyst;
  • α5) a second catalyst; and
  • α6) an polymerization inhibitor;

to yield the Alpha Oligomer;

wherein said Beta Oligomer is synthesized by the reaction of

• • β1) a hydroxyl group containing acrylate;
  • β2) a diisocyanate; and
  • β3) a polyether polyol; in the presence of
  • β4) a catalyst;

wherein said catalyst is selected from the group consisting of dibutyl tin dilaurate; metal carboxylates, including, but not limited to: organobismuth catalysts such as bismuth neodecanoate; zinc neodecanoate; zirconium neodecanoate; zinc 2-ethylhexanoate; sulfonic acids, including but not limited to dodecylbenzene sulfonic acid, methane sulfonic acid; amino or organo-base catalysts, including, but not limited to: 1,2-dimethylimidazole and diazabicyclooctane; triphenyl phosphine; alkoxides of zirconium and titanium, including, but not limited to Zirconium butoxide and Titanium butoxide; and Ionic liquid phosphonium salts; and tetradecyl(trihexyl)phosphonium chloride;

wherein said Gamma Oligomer is an epoxy diacrylate.

Alpha Oligomer

The Alpha Oligomer is typically prepared according to a 2-step synthesis process involving first combining an anhydride with a hydroxyl-containing (meth)acrylate.

The anhydride used to prepare the Alpha Oligomer is selected from the group consisting of hexahydrophthalic anhydride (HHPA), methylhexahydrophthalic anhydride (MHHPA), succinic anhydride (SA), phthalic anhydride (PA), and maleic anhydride (MA), with HHPA being preferred. When preparing the Alpha Oligomer, the anhydride may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 60 wt. %, and preferably from about 5 to about 7 wt. %, based on the total weight of the coating composition.

The hydroxyl-containing (meth)acrylate used to prepare the Alpha Oligomer may be of any suitable type, but typically is a hydroxyl alkyl (meth)acrylate such as hydroxyethyl acrylate (HEA) or an acrylate selected from the group consisting of polypropylene glycol monoacrylate (PPA6), tripropylene glycol monoacrylate (TPGMA), caprolactone acrylates, and pentaerythritol triacrylate (e.g., SR-444). HEA is preferred. When preparing the Alpha Oligomer, the hydroxyl-containing (meth)acrylate may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 60 wt. %, and preferably from about 3 to about 5 wt. %, based on the total weight of the coating composition.

The components typically are reacted at a temperature in the range of from about 90° C. to about 130° C., preferably from about 100° C. to about 120° C., more preferably from about 105° C. to about 115° C. Preferably this step is carried out under air atmosphere, more preferably dry air atmosphere.

In the second step of the 2-step process, an epoxy-containing compound is reacted with the product of step 1. The epoxy-containing compound is a diglycidyl ether, in particular a glycidyl ether of a bisphenol such as EPON resin sold by Hexion Specialty Chemicals including bisphenol A epichlorohydrin epoxy unmodified liquid resins, number average molecular weight=700, sold as EPON 825 and EPON 828 (CAS No. 25068-38-6) and EPOTEC YD-126 and EPOTEC YD-128 bisphenol A epichlorohydrin epoxy resin sold by TRInternational. When preparing the Alpha Oligomer, the epoxy may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 60 wt. %, and preferably from about 5 to about 9 wt. %, based on the total weight of the coating composition.

The second step of the 2-step process desirably is carried out under the same reaction conditions, such as temperature and reaction time, as described for the 1-step process above. Because of the exothermic nature of the anhydride ring-opening reaction, in some embodiments it is desirable to initially react the anhydride compound with only a portion of the acrylate until the desired reaction temperature has been reached. The reaction temperature can thereafter be maintained by adding at a controlled rate, or by drop-wise addition of, the remaining portion of the acrylate. If needed, the reaction can be heated in order to maintain the desired reaction temperature. Typically, the reaction in step 1 of the procedure is carried out within about 2-4 hours and the reaction in step 2 of the procedure is carried out within about 8-15 hours.

A catalyst combination is used to assist the reaction during the preparation of the Alpha Oligomer of the present invention. Specifically, the preparation of the Alpha Oligomer is carried out in the presence of a combination of a triarylphosphine catalyst, such as triphenylphosphine (TPP) or tritolylphosphine, and a tertiary amine catalyst, such as the triethylene triamine catalyst 1,4-diazabicyclo[2.2.2]octane (DABCO). The preferred combination is TPP and DABCO. The concentration of the catalyst combination present in the reaction mixture generally lies between about 0.01 and about 1.0 wt. %, preferably between about 0.005 and about 0.5 wt. %, more preferably between about 0.01 and about 0.4 wt. %, and even more preferably between about 0.015 wt. % and about 0.3 wt. %, based on the total weight of the coating composition. The amount of the first catalyst present in the reaction mixture typically is about 0.001 wt. % to about 1 wt. %, preferably about 0.005 wt. % to about 0.25 wt. %, and the amount of the second catalyst present in the reaction mixture typically is about 0.001 wt. % to about 1 wt. %, preferably about 0.01 wt. % to about 0.05 wt. %, based on the total weight of the coating composition.

The preparation of the Alpha Oligomer is conducted in the presence of a polymerization inhibitor which is used to inhibit the polymerization of acrylate during the reaction. The polymerization inhibitor is selected from the group consisting of butylated hydroxytoluene (BHT), hydroquinone and derivatives thereof such as methylether hydroquinone and 2,5-dibutyl hydroquinone; 3,5-di-tert-butyl-4-hydroxytoluene; methyl-di-tert-butylphenol; 2,6-di-tert-butyl-p-cresol; and the like. The preferred polymerization inhibitor for polymerization is BHT. When preparing the Alpha Oligomer, the polymerization inhibitor may be added to the reaction mixture in an amount ranging from about 0.001 wt. % to about 1 wt. %, and preferably from about 0.01 to about 0.05 wt. %, based on the total weight of the coating composition.

Beta Oligomer

The Beta Oligomer is a urethane oligomer prepared by reaction of an hydroxyl-containing acrylate, an isocyanate, and a polyether polyol in the presence of a catalyst and a polymerization inhibitor

The hydroxyl-containing acrylate can be any of the acrylates described above, and preferably is HEA. When preparing the Beta Oligomer, the hydroxyl-containing acrylate may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 10 wt. %, and preferably from about 3 wt. % to about 5 wt. %, based on the total weight of the coating composition.

The isocyanate may be of any suitable type, e.g., aromatic or aliphatic, but desirably is a diisocyanate. Suitable diisocyanates are known in the art, and include, for example, isophorone diisocyanate (IPDI) and toluene diisocyanate (TDI). Preferably the diisocyanate is TDI. When preparing the Beta Oligomer, the isocyanate may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 25 wt. %, and preferably from about 4 wt. % to about 6 wt. %, based on the total weight of the coating composition.

The polyether polyol is selected from the group consisting of polyethylene glycol and polypropylene glycol. Preferably the polyether polyol is a polypropylene glycol having a number average molecular weight of about 300 g/mol to about 5,000 g/mol, and more preferably a polypropylene glycol having a number average molecular weight of about 1000 (e.g., Pluracol P1010 polypropylene glycol available from BASF). When preparing the Beta Oligomer, the polyether polyol may be added to the reaction mixture in an amount ranging from about 25 wt. % to about 95 wt. %, and preferably from about 55 wt. % to about 75 wt. %, based on the total weight of the coating composition.

The polymerization inhibitor can be any of those described above, and preferably is BHT. When preparing the Beta Oligomer, the polymerization inhibitor may be added to the reaction mixture in an amount ranging from about 0.01 wt. % to about 1 wt. %, and preferably from about 0.02 to about 0.08 wt. %, based on the total weight of the coating composition.

The preparation of the Beta Oligomer is conducted in the presence of a urethanization catalyst wherein said catalyst is selected from the group consisting of copper naphthenate, cobalt naphthenate, zinc naphthenate, triethylamine, triethylenediamine, 2-methyltriethyleneamine, dibutyl tin dilaurate (DBTDL); metal carboxylates, including, but not limited to: organobismuth catalysts such as bismuth neodecanoate, CAS 34364-26-6; zinc neodecanoate, CAS 27253-29-8; zirconium neodecanoate, CAS 39049-04-2; and zinc 2-ethylhexanoate, CAS 136-53-8; sulfonic acids, including but not limited to dodecylbenzene sulfonic acid, CAS 27176-87-0; and methane sulfonic acid, CAS 75-75-2; amino or organo-base catalysts, including, but not limited to: 1,2-dimethylimidazole, CAS 1739-84-0; and diazabicyclo[2.2.2]octane (DABCO), CAS 280-57-9 (strong base); and triphenyl phosphine; alkoxides of zirconium and titanium, including, but not limited to zirconium butoxide, (tetrabutyl zirconate) CAS 1071-76-7; and titanium butoxide, (tetrabutyl titanate) CAS 5593-70-4; and ionic liquid phosphonium, imidazolium, and pyridinium salts, such as, but not limited to, trihexyl(tetradecyl)phosphonium hexafluorophosphate, CAS No. 374683-44-0; 1-butyl-3-methylimidazolium acetate, CAS No. 284049-75-8; and N-butyl-4-methylpyridinium chloride, CAS No. 125652-55-3; and tetradecyl(trihexyl)phosphonium.

The catalyst used to prepare the Beta Oligomer preferably is DBTDL.

The catalyst may be used in the free, soluble, and homogeneous state, or may be tethered to inert agents such as silica gel, or divinyl crosslinked macroreticular resins, and used in the heterogeneous state to be filtered at the conclusion of oligomer synthesis.

When preparing the Beta Oligomer, the catalyst may be added to the reaction mixture in an amount ranging from about 0.001 wt. % to about 0.5 wt. %, and preferably from about 0.005 wt. % to about 0.025 wt. %, based on the total weight of the coating composition.

Gamma Oligomer

The Gamma Oligomer is an epoxy diacrylate. Preferably the Gamma Oligomer is a bisphenol A based epoxy diacrylate oligomer, for example CN120 or CN120Z oligomer sold by Sartomer. More preferably the Gamma Oligomer is CN120Z. The Gamma Oligomer may be added to the reaction mixture in an amount ranging from about 1 wt. % to about 50 wt. %, and preferably from about 20 wt. % to about 30 wt. %, based on the total weight of the coating composition.

In preparing the radiation curable Secondary Coating of the invention, the Beta Oligomer is typically synthesized first and then stored. Next, the Alpha Oligomer is synthesized. Finally, the Beta Oligomer and Gamma Oligomer are added to the Alpha Oligomer to form the Secondary Coating Oligomer Blend.

Radiation Curable Secondary Coating Composition

The Alpha Oligomer, Beta Oligomer, and Gamma Oligomer of the invention are blended to form a Secondary Coating Oligomer Blend, which is then mixed with a first and second diluent monomer, an antioxidant, a combination of a first and second photoinitiator, and optionally a slip additive or a blend of slip additives in order to form a Secondary Coating.

The first diluent and second diluent are monomers having an acrylate or vinyl ether functionality and a C₄-C₂₀ alkyl or polyether moiety. Particular examples of such diluents include hexylacrylate, 2-ethylhexylacrylate, isobornylacrylate, decylacrylate, laurylacrylate, stearylacrylate, 2-ethoxyethoxyethylacrylate, laurylvinylether, 2-ethylhexylvinyl ether, isodecyl acrylate, isooctyl acrylate, N-vinyl-caprolactam, N-vinylpyrrolidone, tripropylene glycol acrylate, tripropylene glycol diacrylate, acrylamides, and the alkoxylated derivatives, such as, ethoxylated lauryl acrylate, ethoxylated isodecyl acrylate, and the like. The first diluent preferably is isobornyl acrylate (e.g., SR506D sold by Sartomer) and the second diluent preferably is tripropylene glycol diacrylate (e.g., SR306HP sold by Sartomer). In some embodiments, diluent monomer is added to the coating composition in addition to the first and second diluent monomers. Diluent monomer may be added to the coating composition in an amount ranging from about 5 wt. % to about 80 wt. %, and preferably from about 10 wt. % to about 40 wt. %, based on the total weight of the coating composition. The amount of the first diluent present in the coating composition typically is about 5 wt. % to about 80 wt. %, preferably about 5 wt. % to about 7 wt. %, and the amount of the second diluent present in the coating composition typically is about 5 wt. % to about 80 wt. %, preferably about 20 wt. % to about 25 wt. %, based on the total weight of the coating composition.

The antioxidant is a sterically hindered phenolic compound, for example 2,6-ditertiarybutyl-4-methylphenol, 2,6-ditertiarybutyl-4-ethyl phenol, 2,6-ditertiarybutyl-4-n-butyl phenol, 4-hydroxymethyl-2,6-ditertiarybutyl phenol, and such commercially available compounds as thiodiethylene bis(3,5-ditertiarybutyl-4-hydroxyl)hydrocinnamate, octadecyl-3,5-ditertiarybutyl-4-hydroxyhydrocinnamate, 1,6-hexamethylene bis(3,5-ditertiarybutyl-4-hydroxyhydrocinnamate), and tetrakis(methylene(3,5-ditertiary-butyl-4-hydroxyhydrocinnamate))methane, all available as Irganox 1035, 1076, 259 and 1010, respectively, from Ciba Geigy. Other examples of sterically hindered phenolics useful herein include 1,3,5-trimethyl-2,4,6-tris(3,5-ditertiarybutyl-4-hydroxybenzyl)benzene and 4,4′-methylene-bis(2,6-ditertiarybutylphenol), available as Ethyl 330 and 702, respectively, from Ethyl Corporation. The preferred antioxidant is thiodiethylene bis(3,5-ditertiarybutyl-4-hydroxyl)hydrocinnamate (e.g., Irganox 1035).

The first photoinitiator is an α-hydroxyketo-type photoinitiators such as 1-hydroxycyclohexyl phenyl ketone (e.g., Irgacure 184, available from Ciba Geigy; Chivacure 184, available from Chitec Chemicals), 2-hydroxy-2-methyl-1-phenyl-propan-1-one (e.g., Darocur 1173, available from Ciba Geigy), 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butan-1-one, 2,2-dimethoxy-2-phenyl-acetophenone, 2-methyl-1-[4-(methylthio)phenyl]-2-(4-morpholinyl)-1-propanone, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropan-1-one (e.g., Irgacure 907, available from Ciba Geigy), 4-(2-hydroxyethoxy)phenyl-2-hydroxy-2-propyl ketone dimethoxy-phenylacetophenone, 1-(4-isopropylphenyl)-2-hydroxy-2-methyl-propan-1-one, 1-(4-dodecylphenyl)-2-hydroxy-2-methylpropan-1-one, and 4-(2-hydroxyethoxy)phenyl-2-(2-hydroxy-2-propyl)ketone. Preferably the first photoinitiator is 1-hydroxycyclohexyl phenyl ketone (e.g., Irgacure 184).

The second photoinitiator is a phosphine oxide type photoinitiator, such as 2,4,6-trimethylbenzoyl-diphenylphosphine oxide type (TPO) (e.g., Lucirin TPO available from BASF or Darocur TPO, available from Ciba Geigy), bis(2,4,6-trimethylbenzoyl)phenyl-phosphine oxide (e.g., Irgacure 819, available from Ciba Geigy), or bisacyl phosphine oxide type (BAPO) photoinitiators. Preferably the second photoinitiator is TPO.

Slip Additives are commercially available. The preferred blend of slip additives is a blend of DC-57 siloxane sold by Dow Corning which is dimethylmethyl(propyl-(poly(EO))acetate)siloxane (CAS Registry No. 70914-12-4) and DC-190 siloxane blend sold by Dow Corning which is a mixture of from about 40.0 to about 70.0 wt. % dimethylmethyl-(propyl(poly(EO)(PO))acetate) siloxane (CAS Registry No. 68037-64-9), from about 30.0 to about 60.0 wt. % of poly(ethylene oxide propylene oxide)monoallylether acetate (CAS Registry No. 56090-69-8), and less than about 9.0 wt. % polyether polyol acetate (CAS Registry No. 39362-51-1).

A preferred weight percent of each component of the Radiation Curable Secondary Coating Composition of the instant claimed invention is as follows:

Alpha Oligomer
anhydride                        from about 5 to about 7 wt. %
hydroxyl-containing (meth)acrylate from about 3 to about 5 wt. %
epoxy                            from about 5 to about 9 wt. %
first catalyst                   from about 0.005 to about 0.25 wt. %
second catalyst                  from about 0.01 to about 0.05 wt. %
polymerization inhibitor         from about 0.01 to about 0.05 wt. %

Beta Oligomer
hydroxyl-containing      from about 3 to about 5 wt. %
(meth)acrylate
Isocyanate               from about 4 to about 6 wt. %
polyether polyol         from about 13 to about 17 wt. %
polymerization inhibitor from about 0.01 to about 0.05 wt. %
Catalyst                 from about 0.005 to about 0.025 wt. %

Gamma Oligomer
epoxy diacrylate from about 20 to about 30 wt. %

Other Additives
first diluent monomer     from about 5 to about 7 wt. %
second diluent monomer    from about 20 to about 25 wt. %
antioxidant               from about 0.25 to about 1.25 wt. %
first photoinitiator      from about 1 to about 4 wt %
second photoinitiator     from about 0.25 to about 0.95 wt. %
slip additives (optional) from about 0.35 to about 0.75 wt. %

A more preferred weight percent of each component of the Radiation Curable Secondary Coating Composition of the instant claimed invention is as follows:

Alpha Oligomer	47.94	wt. %
anhydride (e.g., HHPA)	6.86	wt. %
hydroxyl-containing (meth)acrylate (e.g., HEA)	4.3	wt. %
epoxy (e.g., EPOTEC YD-126 or EPOTEC YD-128)	7.91	wt. %
first catalyst (e.g., DABCO)	0.01	wt. %
second catalyst (e.g., TPP)	0.03	wt. %
polymerization inhibitor (e.g., BHT)	0.03	wt. %

Beta Oligomer	24.87	wt. %
hydroxyl-containing (meth)acrylate (e.g., HEA)	4.3	wt. %
diisocyanate (e.g., TDI)	5.12	wt. %
polyether polyol (e.g., P1010)	15.44	wt. %
polymerization inhibitor	from about 0.01 to about
	0.05 wt. %
catalyst (e.g., DBTDL)	0.01	wt. %

Gamma Oligomer
epoxy diacrylate (e.g., CN120Z) 23 wt. %

	Other Additives	4.52	wt. %
	first diluent monomer (e.g.,	6	wt. %
	isobornyl acrylate)
	second diluent monomer (e.g.,	22.98	wt. %
	tripropylene glycol diacrylate)
	antioxidant (e.g., Irganox 1035)	0.5	wt. %
	first photoinitiator (e.g.,	2.76	wt. %
	Irgacure 184)
	second photoinitiator (e.g., TPO)	0.76	wt. %
	slip additives (e.g., DC-57 +	0.5 wt. %
	DC-190)	(0.17 wt. % + 0.33 wt. %)
	Total	100.33	wt. %*
	*0.33 of other ingredients is not present when the optional blend of slip additives is present

After a commercial Primary Coating is found, it may be applied directly onto the surface of the optical fiber. The radiation curable Primary Coating may be any commercially available radiation curable Primary Coating for optical fiber. Such commercially available radiation curable Primary Coatings are available from DSM Desotech Inc., and others, including, but without being limited to Hexion, Luvantix and PhiChem.

Then the secondary coating is applied on top of the primary coating, the radiation is applied and the secondary coating is cured. When the instant claimed invention is applied as a secondary coating, the preferred type of radiation is UV. This secondary coating of the instant claimed invention is referred to as the R Secondary Coating.

After the secondary coating is cured, a layer of “ink coating” is typically applied and then the coated and inked optical fiber is placed alongside other coated and inked optical fibers in a “ribbon assembly” and a radiation curable matrix coating is used to hold the optical fibers in the desired location in the ribbon assembly.

Secondary Coating Properties

A Secondary Coating produced from the coating composition according to the invention will desirably have properties such as modulus, toughness and elongation suitable for coating optical fiber.

The Secondary Coating typically has toughness greater than about 12 J/m³, a secant modulus of less than about 1500 MPa, and a T_g greater than about 50° C. Preferably, the Secondary Coating has toughness greater than about 14 J/m³, a secant modulus of from about 200 MPa to about 1200 MPa, and a T_g greater than about 60° C. More preferably, the Secondary Coating has a toughness greater than about 16 J/m³, a secant modulus of from about 400 MPa to about 1000 MPa, and a T_g greater than about 70° C. The Secondary Coating preferably has an elongation of from about 30% to about 80%. In addition, preferably the Secondary Coating shows a change in equilibrium modulus of about 20% or less when aged for 60 days at 85° C. and 85% relative humidity. The modulus, as is well known, is the rate of change of strain as a function of stress. This is represented graphically as the slope of the straight line portion of a stress-strain diagram. The modulus may be determined by use of any instrument suitable for providing a stress-strain curve of sample. Instruments suitable for this analysis include those manufactured by Instron, Inc., and include the Instron 5564. In determining the modulus of the cured coating compositions in accordance with the invention, a sample of the radiation-curable composition is drawn onto a plate to provide a thin film, or alternatively formed into a rod using a cylindrical template. The sample is then exposed to radiation to affect cure. One (or more, if an average value is desired) film sample is cut from the cured film. The sample(s) should be free of significant defects, e.g., holes, jagged edges, substantial non-uniform thickness. Opposite ends of the sample are then attached to the instrument. During testing, a first end of the sample remains stationary, while the instrument moves the second end away from the first end at what may be referred to as a crosshead speed. The crosshead speed, which may initially be set at 1 inch/minute, may be altered if found to be inappropriate for a particular sample, e.g., a high modulus film breaks before an acceptable stress-strain curve is obtained. After setup is completed, the testing is then commenced, with the instrument providing a stress-strain curve, modulus and other data. It is important to note that toughness can be measured in several ways. One way includes a tensile modulus of toughness that is based on the ability of material to absorb energy up to the point of rupture, and that is determined by measuring the area under the stress-strain curve. Another way to measure toughness is fracture toughness based on tear strength that requires starting with a pre-defined infinitely sharp crack of a certain length, and that uses a critical stress intensity factor resulting from the resistance of the material to crack propagation.

The invention will be further explained by way of the following examples, without being limited thereto.

EXAMPLES

Tensile Strength, Elongation and Modulus Test Method: The tensile properties (tensile strength, percent elongation at break, and modulus) of cured samples of the radiation curable Secondary Coatings for optical fiber are tested on films using a universal testing instrument, Instron Model 4201 equipped with a suitable personal computer and Instron software to yield values of tensile strength, percent elongation at break, and secant or segment modulus. Samples are prepared for testing by curing a 75-μm film of the material using a Fusion UV processor. A quick summary of the set-up for the Fusion UV processor is as follows:

Lamps: D

Intensity 120 W/cm

Intensity meter IL390

Dose 1.0 J/cm²

Atmosphere Nitrogen

Conditioning time in 50% humidity 16-24 hours

Samples are cured at 1.0 J/cm² in a nitrogen atmosphere. Test specimens having a width of 0.5 inches and a length of 5 inches are cut from the film. The exact thickness of each specimen is measured with a micrometer. For relatively soft coatings (e.g., those with a modulus of less than about 10 MPa), the coating is drawn down and cured on a glass plate and the individual specimens cut from the glass plate with a scalpel. A 2-lb load cell is used in the Instron and modulus is calculated at 2.5% elongation with a least squares fit of the stress-strain plot. Cured films are conditioned at 23±1° C. and 50±5% relative humidity for between 16 and 24 hours prior to testing.

For relatively harder coatings, the coating is drawn down on a Mylar film and specimens are cut with a Thwing Albert 0.5-inch precision sample cutter. A 20-lb load cell is used in the Instron and modulus is calculated at 2.5% elongation from the secant at that point. Cured films are conditioned at 23±1° C. and 50±5% relative humidity for between 16 and 24 hours prior to testing. For testing specimens, the gage length is 2-inches and the crosshead speed is 1.00 inches/minute. All testing is done at a temperature of 23±1° C. and a relative humidity of 50±5%. All measurements are determined from the average of at least 6 test specimens.

DMA Test Method: Dynamic Mechanical Analysis (DMA) is carried out on the test samples, using an RSA-II instrument manufactured by Rheometric Scientific Inc. A free film specimen (typically about 36 mm long, 12 mm wide, and 0.075 mm thick) is mounted in the grips of the instrument, and the temperature initially brought to 80° C. and held there for about five minutes. During the latter soak period at 80° C., the sample is stretched by about 2.5% of its original length. Also during this time, information about the sample identity, its dimensions, and the specific test method is entered into the software (RSI Orchestrator) residing on the attached personal computer.

All tests are performed at a frequency of 1.0 radians, with the dynamic temperature step method having 2° C. steps, a soak time of 5 to 10 seconds, an initial strain of about 0.001 (ΔL/L), and with autotension and autostrain options activated. The autotension is set to ensure that the sample remained under a tensile force throughout the run, and autostrain is set to allow the strain to be increased as the sample passed through the glass transition and became softer. After the 5 minute soak time, the temperature in the sample oven is reduced in 20° C. steps until the starting temperature, typically −80° C. or −60° C., is reached. The final temperature of the run is entered into the software before starting the run, such that the data for a sample would extend from the glassy region through the transition region and well into the rubbery region.

The run is started and allowed to proceed to completion. After completion of the run, a graph of E′, E″, and tan □, all versus temperature, appeared on the computer screen. The data points on each curve are smoothed, using a program in the software. On this plot, three points representing the glass transition are identified: 1) The temperature at which E′=1000 MPa; 2) The temperature at which E′=100 MPa; 3) The temperature of the peak in the tan □ curve. If the tan □ curve contained more than one peak, the temperature of each peak is measured. One additional value obtained from the graph is the minimum value for E′ in the rubbery region. This value is reported as the equilibrium modulus, E₀.

Water Sensitivity Test Method: A layer of the composition is cured to provide a UV cured coating test strip (1.5 inch×1.5 inch×0.6 mils). The test strip is weighed and placed in a vial containing deionized water, which is subsequently stored for 3 weeks at 23° C. At periodic intervals, e.g. 30 minutes, 1 hour, 2 hours, 3 hours, 6 hours, 1 day, 2 days, 3 days, 7 days, 14 days, and 21 days, the test strip is removed from the vial and gently patted dry with a paper towel and reweighed. The percent water absorption is reported as 100*(weight after immersion-weight before immersion)/(weight before immersion). The peak water absorption is the highest water absorption value reached during the 3-week immersion period. At the end of the 3-week period, the test strip is dried in a 60° C. oven for 1 hour, cooled in a desiccator for 15 minutes, and reweighed. The percent water extractables is reported as 100*(weight before immersion-weight after drying)/(weight before immersion). The water sensitivity is reported as |peak water absorption|+|water extractables|. Three test strips are tested to improve the accuracy of the test.

Refractive Index Test Method: The refractive index of the cured compositions is determined with the Becke Line method, which entails matching the refractive index of finely cut strips of the cured composition with immersion liquids of known refraction properties. The test is performed under a microscope at 23° C. and with light having a wavelength of 589 nm.

Viscosity Test Method: The viscosity is measured using a Physica MC10 Viscometer. The test samples are examined and if an excessive amount of bubbles is present, steps are taken to remove most of the bubbles. Not all bubbles need to be removed at this stage, because the act of sample loading introduces some bubbles. The instrument is set up for the conventional Z3 system, which is used. The samples are loaded into a disposable aluminum cup by using the syringe to measure out 17 cm³. The sample in the cup is examined and if it contains an excessive amount of bubbles, they are removed by a direct means such as centrifugation, or enough time is allowed to elapse to let the bubbles escape from the bulk of the liquid. Bubbles at the top surface of the liquid are acceptable. The bob is gently lowered into the liquid in the measuring cup, and the cup and bob are installed in the instrument. The sample temperature is allowed to equilibrate with the temperature of the circulating liquid by waiting five minutes. Then, the rotational speed is set to a desired value which will produce the desired shear rate. The desired value of the shear rate is easily determined by one of ordinary skill in the art from an expected viscosity range of the sample. The shear rate is typically 50 sec⁻¹ or 100 sec⁻¹. The instrument panel reads out a viscosity value, and if the viscosity value varied only slightly (less than 2% relative variation) for 15 seconds, the measurement is complete. If not, it is possible that the temperature had not yet reached an equilibrium value, or that the material is changing due to shearing. If the latter case, further testing at different shear rates will be needed to define the sample's viscous properties. The results reported are the average viscosity values of three test samples. The results are reported either in centipoises (cps) or milliPascal·seconds (mPa·s), which are equivalent.

Examples 1-3

Three different batches of R Secondary Coating in accordance with the invention (Examples 1, 2, and 3) are prepared and the physical properties are evaluated. The tensile properties of cured Secondary Coatings are tested on rods following the method described in U.S. Pat. No. 6,862,392, which is incorporated herein by reference. The rods are prepared by filling elastomeric clear silicone rubber tubing with the coating composition and exposing the composition to one Joule of UV radiation from a D lamp under nitrogen purge.

If the tubes are rotated 180°, then it is not required that the tubes be cured on aluminum foil. If the tubes are not rotated 180°, then the tubes are to be cured on aluminum foil.

The rods are recovered from the tubing by gently stretching the tube from the end of the rod and cutting the empty portion of the tube with a razor blade. The end of the rod is then grasped using forceps and the tubing was slowly pulled off of the rod.

The tensile strength, elongation, tensile modulus, toughness, E_max, and viscosity for Secondary Coating compositions

		Example	Example	Example
Tensile Properties	Test Method	1	2	3
Tensile Strength	U.S. Pat. No.	59	62.2	55.7
(MPa)	6,862,392
% Elongation at	U.S. Pat. No.	47.3	41.3	37.0
Break (%)	6,862,392
Tensile Modulus	U.S. Pat. No.	1047.2	1142.1	1091.0
(MPa)	6,862,392
Toughness (J/m3)	U.S. Pat. No.	21	19.5	15.7
	6,862,392
Emax = %	U.S. Pat. No.	56.3	54.5	40.9
	6,862,392

DMA	Test Method	Ex. 1	Ex. 2	Ex. 3
Temp @ E′ = 1000 Mpa (° C.)	DMA test	47.5	46.5	46.1
Temp @ E′ = 100 Mpa (° C.)	DMA test	80.6	78.1	79.5
Temp @ Tan δmax (° C.)	DMA test	76.8	75.4	77.2
Eq. Modulus	MPa	MPa	MPa	MPa
Eq. Modulus (MPa)		39.2	37.4	38.6

		Ex. 1	Ex. 2	Ex. 3
Viscosity	Test Method	(mPa · s)	(mPa · s)	(mPa · s)
25° C.	Viscosity	6797	7076	7033
35° C.	Viscosity	2400	2385	2480
45° C.	Viscosity	984	945	1012
55° C.	Viscosity	466	439	476
65° C.	Viscosity	231	218	230

Draw Tower Simulator Discussion

In the early years of optical fiber coating developments, all newly developed Primary and Secondary Coatings were first tested for their cured film properties and then submitted for evaluation on fiber drawing towers. Out of all the coatings that were requested to be drawn, it was estimated that at most 30% of them were tested on the draw tower, due to high cost and scheduling difficulties. The time from when the coating was first formulated to the time of being applied to glass fiber was typically about 6 months, which greatly slowed the product development cycle.

It is known in the art of radiation cured coatings for optical fiber that when either the Primary Coating or the Secondary Coating was applied to glass fiber, its properties often differ from the flat film properties of a cured film of the same coating. This is believed to be because the coating on fiber and the coating flat film have differences in sample size, geometry, UV intensity exposure, acquired UV total exposure, processing speed, temperature of the substrate, curing temperature, and possibly nitrogen inserting conditions.

Equipment that would provide similar curing conditions as those present at fiber manufacturers, in order to enable a more reliable coating development route and faster turnaround time has been developed. This type of alternative application and curing equipment needed to be easy to use, low maintenance, and offer reproducible performance. The name of the equipment is a “draw tower simulator” hereinafter abbreviated “DTS”. Draw tower simulators are custom designed and constructed based on detailed examination of actual glass fiber draw tower components. All the measurements (lamp positions, distance between coating stages, gaps between coating stages and UV lamps, etc) are duplicated from glass fiber drawing towers. This helps mimic the processing conditions used in fiber drawing industry.

One known DTS is equipped with five Fusion F600 lamps—two for the upper coating stage and three for the lower. The second lamp in each stage can be rotated at various angles between 15-135°, allowing for a more detailed study of the curing profile.

The “core” used for the known DTS is 130.0±1.0 μm stainless steel wire. Fiber drawing applicators of different designs, from different suppliers, are available for evaluation. This configuration allows the application of optical fiber coatings at similar conditions that actually exist at industry production sites.

The draw tower simulator has already been used to expand the analysis of radiation curable coatings on optical fiber. A method of measuring the Primary Coating's in-situ modulus that can be used to indicate the coating's strength, degree of cure, and the fiber's performance under different environments in 2003 was reported by P. A. M. Steeman, J. J. M. Slot, H. G. H. van Melick, A. A. F. v. d. Ven, H. Cao, and R. Johnson, in the Proceedings of the 52nd IWCS, p. 246 (2003). In 2004, Steeman et al reported on how the rheological high shear profile of optical fiber coatings can be used to predict the coatings' processability at faster drawing speeds P. A. M. Steeman, W. Zoetelief, H. Cao, and M. Bulters, Proceedings of the 53rd IWCS, p. 532 (2004). The draw tower simulator can be used to investigate further the properties of primary and Secondary. Coatings on an optical fiber.

These test methods are useful for coatings on wire or coatings on optical fiber:

% RAU Secondary Test Method: The degree of cure on the outer coating on an optical fiber is determined by FTIR using a diamond ATR accessory. FTIR instrument parameters include: 100 co-added scans, 4 cm⁻¹ resolution, DTGS detector, a spectrum range of 4000-650 cm⁻¹, and an approximately 25% reduction in the default mirror velocity to improve signal-to-noise. Two spectra are required; one of the uncured liquid coating that corresponds to the coating on the fiber and one of the outer coating on the fiber. The spectrum of the liquid coating is obtained after completely covering the diamond surface with the coating. The liquid should be the same batch that is used to coat the fiber if possible, but the minimum requirement is that it must be the same formulation. The final format of the spectrum should be in absorbance.

The fiber is mounted on the diamond and sufficient pressure is put on the fiber to obtain a spectrum suitable for quantitative analysis. For maximum spectral intensity, the fiber should be placed on the center of the diamond parallel to the direction of the infrared beam. If insufficient intensity is obtained with a single fiber, 2-3 fibers may be placed on the diamond parallel to each other and as close as possible. The final format of the spectrum should be in absorbance.

For both the liquid and the cured coating, measure the peak area of both the acrylate double bond peak at 810 cm⁻¹ and a reference peak in the 750-780 cm⁻¹ region. Peak area is determined using the baseline technique where a baseline is chosen to be tangent to absorbance minima on either side of the peak. The area under the peak and above the baseline is then determined. The integration limits for the liquid and the cured sample are not identical but are similar, especially for the reference peak.

The ratio of the acrylate peak area to the reference peak area is determined for both the liquid and the cured sample. Degree of cure, expressed as percent reacted acrylate unsaturation (% RAU), is calculated from the equation below:

$\%RAU=\frac{\left(R_L-R_F\right)\times 100}{R_L}$

where R_L is the area ratio of the liquid sample and RF is the area ratio of the cured outer coating.

In-situ Modulus of Secondary Coating Test Method: The in-situ modulus of a Secondary Coating on a dual-coated (soft Primary Coating and hard Secondary Coating) glass fiber or a metal wire fiber is measured by this test method. For sample preparation, strip ˜2 cm length of the coating layers off the fiber as a complete coating tube from one end of the coated fiber by first dipping the coated fiber end along with the stripping tool in liquid N₂ for at least 10 seconds and then strip the coating tube off with a fast motion while the coating layers are still rigid. A DMA (Dynamic Mechanical Analysis) instrument: Rheometrics Solids Analyzer (RSA-II) is used to measure the modulus of the Secondary Coating. For dual-coated fiber, Secondary Coating has much higher modulus than the Primary Coating; therefore the contribution from the Primary Coating on the dynamic tensile test results performed on the coating tube can be ignored. For RSA-II where the distance adjustment between the two grips is limited, the coating tube sample may be shorter than the distance between the two grips. A simple sample holder made by a metal plate folded and tightened at the open end by a screw is used to tightly hold the coating tube sample from the lower end. Slide the fixture into the center of the lower grip and tighten the grip. Using tweezers to straighten the coating tube to upright position through the upper grip. Close and tighten the upper grip. Adjust the strain offset until the pretension is ˜10 g.

The tests are conducted at room temperature (˜23° C.). Under the dynamic tensile test mode of DMA, the test frequency is set at 1.0 radian/second; the strain is 5E-4. The geometry type is selected as cylindrical. The sample length is the length of the coating tube between the upper edge of the metal fixture and the lower grip, 11 mm in our test. The diameter (D) is entered to be 0.16 mm according to the following equation:

D=2×√{square root over (R_s²−R_p²)}

where R_s and R_p are secondary and Primary Coating outer radius respectively. The geometry of a standard fiber, R_s=122.5 μm and R_p=92.5 μm, is used for the calculation. A dynamic time sweep is run and 5 data points of tensile storage modulus E are recorded. The reported E is the average of all data points. This measured modulus E is then corrected by multiplying a correction factor which used the actual fiber geometry. The correction factor is (122.5²−92.5²)/(R_s^actual−R_p^actual). For glass fibers, actual fiber geometry including R_s and R_p values is measured by PK2400 Fiber Geometry System. For wire fibers, R_s and R_p are measured under microscope. The reported E is the average of three test samples.

In-situ T_g Measurement Of Primary and Secondary Coatings Test Method: The glass transition temperatures (T_g) of primary and Secondary Coatings on a dual-coated glass fiber or a metal wire fiber are measured by this method. These glass transition temperatures are referred to as “Tube Tg”.

For sample preparation, strip ˜2 cm length of the coating layers off the fiber as a complete coating tube from one end of the coated fiber by first dipping the coated fiber end along with the stripping tool in liquid N₂ for at least 10 seconds and then strip the coating tube off with a fast motion while the coating layers are still rigid.

A DMA (Dynamic Mechanical Analysis) instrument: Rheometrics Solids Analyzer (RSA-II) is used. For RSA-II, the gap between the two grips of RSAII can be expanded as much as 1 mm. The gap is first adjusted to the minimum level by adjusting strain offset. A simple sample holder made by a metal plate folded and tightened at the open end by a screw is used to tightly hold the coating tube sample from the lower end. Slide the fixture into the center of the lower grip and tighten the grip. Using tweezers to straighten the coating tube to upright position through the upper grip. Close and tighten the upper grip. Close the oven and set the oven temperature to a value higher than the T_g for Secondary Coating or 100° C. with liquid nitrogen as temperature control medium. When the oven temperature reached that temperature, the strain offset is adjusted until the pretension was in the range of 0 g to 0.3 g.

Under the dynamic temperature step test of DMA, the test frequency is set at 1.0 radian/second; the strain is 5E-3; the temperature increment is 2° C. and the soak time is 10 seconds. The geometry type is selected as cylindrical. The geometry setting was the same as the one used for secondary in-situ modulus test. The sample length is the length of the coating tube between the upper edge of the metal fixture and the lower grip, 11 mm in our test. The diameter (D) is entered to be 0.16 mm according to the following equation:

D=2×√{square root over (R_s²−R_p²)}

where R_s and R_p are secondary and Primary Coating outer radius respectively. The geometry of a standard fiber, R_s=122.5 μm and R_p=92.5 μm, is used for the calculation.

A dynamic temperature step test is run from the starting temperature (100° C. in our test) till the temperature below the Primary Coating T_g or −80° C. After the run, the peaks from tan δ curve are reported as Primary Coating T_g (corresponding to the lower temperature) and Secondary Coating T_g (corresponding to the higher temperature). Note that the measured glass transition temperatures, especially for primary glass transition temperature, should be considered as relative values of glass transition temperatures for the coating layers on fiber due to the tan δ shift from the complex structure of the coating tube.

Draw Tower Simulator Examples

A commercially available radiation curable Primary Coating and various embodiments of the instant claimed Secondary Coating are applied to wire using a Draw Tower Simulator. The wire is run at five different line speeds, 750 meters/minute, 1200 meters/minute, 1500 meters/minute, 1800 meters/minute and 2100 meters/minute.

Drawing is carried out using either wet on dry or wet on wet mode. Wet on dry mode means the liquid Primary Coating is applied wet, and then the liquid Primary Coating is cured to a solid layer on the wire. After the Primary Coating is cured, the Secondary Coating is applied and then cured as well. Wet on wet mode means the liquid Primary Coating is applied wet, then the Secondary Coating is applied wet and then both the Primary Coating and Secondary Coatings are cured.

Multiple runs are conducted with a commercially available radiation curable Primary Coating and compositions of the instant claimed Secondary Coating. The cured Secondary Coating on the wire is tested for initial % RAU, initial in-situ modulus and initial Tube Tg. The coated wire is then aged for one month at 85° C. and 85% relative humidity. The cured Secondary Coating on the wire is then tested for % RAU, in-situ modulus and Tube Tg.

Set-Up Conditions for the Draw Tower Simulator:

Zeidl dies are used. S99 for the 10 and S105 for the 2°.

750, 1000, 1200, 1500, 1800, and 2100 m/min are the speeds.

5 lamps are used in the wet on dry process and 3 lamps are used in the wet on wet process.

• • (2) 600 W/in² D Fusion UV lamps are used at 100% for the 1° coatings.
  • (3) 600 W/in² D Fusion UV lamps are used at 100% for the 2° coatings.

Temperatures for the two coatings are 30° C. The dies are also set to 30° C.

Carbon dioxide level is 7 liters/min at each die.

Nitrogen level is 20 liters/min at each lamp.

Pressure for the 1° coating is 1 bar at 25 m/min and goes up to 3 bar at 1000 m/min.

Pressure for the 2° coating is 1 bar at 25 m/min and goes up to 4 bar at 1000 m/min.

The cured radiation curable D Secondary Coating on wire is found to have the following properties:

Line Speed	% RAU Secondary	% RAU Secondary
(m/min)	(Initial)	(1 month)
750	90-94	94-98
1200	86-90	91-95
1500	82-86	90-94
1800	83-87	89-93
2100	80-84	89-93

		In-situ Modulus
Line Speed	In-situ Modulus	Secondary (GPa)
(m/min)	Secondary (GPa)	(1 month)
750	1.30-1.70	1.40-1.90
1200	1.00-1.40	1.50-1.70
1500	1.00-1.40	1.30-1.70
1800	1.00-1.40	1.10-1.50
2100	0.60-1.00	1.00-1.40

	Secondary Tube	Secondary Tube Tg
Line Speed	Tg values (° C.)	values (° C.)
(m/min)	(initial)	(1 month)
750	68-80	68-80
1200	65-69	67-71
1500	60-64	61-65
1800	61-65	61-65
2100	50-58	55-59

It is now possible to describe and claim a wire coated with a first and second layer, wherein the first layer is a cured radiation curable Primary Coating that is in contact with the outer surface of the wire and the second layer is a cured radiation curable Secondary Coating of the instant claimed invention in contact with the outer surface of the Primary Coating,

wherein the cured Secondary Coating on the wire has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:

• • A) a % RAU of from about 80% to about 98%;
  • B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and
  • C) a Tube Tg, of from about 50° C. to about 80° C.

Using this information it is also possible to describe and claim an optical fiber coated with a first and second layer, wherein the first layer is a cured radiation curable Primary Coating that is in contact with the outer surface of the optical fiber and the second layer is a cured radiation curable Secondary Coating of the instant claimed invention in contact with the outer surface of the Primary Coating,

wherein the cured Secondary Coating on the optical fiber has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:

• • A) a % RAU of from about 80% to about 98%;
  • B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and
  • C) a Tube Tg, of from about 50° C. to about 80° C.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A Radiation Curable Secondary Coating composition, wherein said composition comprises

A) a Secondary Coating Oligomer Blend, which is mixed with

B) a first diluent;

C) a second diluent;

D) an antioxidant;

E) a first photoinitiator;

F) a second photoinitiator; and

G) optionally a slip additive or a blend of slip additives;

wherein said Secondary Coating Oligomer Blend comprises:

α) an Alpha Oligomer;

β) a Beta Oligomer;

γ) a Gamma Oligomer;

wherein said Alpha Oligomer is synthesized by the reaction of

α1) an anhydride with

α2) a hydroxyl group containing acrylate;

and the reaction product of α1) and α2) is then reacted further with

α3) an epoxy; in the presence of

α4) a first catalyst;

α5) a second catalyst; and

α6) an polymerization inhibitor;

to yield the Alpha Oligomer;

wherein said Beta Oligomer is synthesized by the reaction of

β1) a hydroxyl group containing acrylate;

β2) a diisocyanate; and

β3) a polyether polyol; in the presence of

β4) a catalyst;

wherein said catalyst is selected from the group consisting of copper naphthenate, cobalt naphthenate, zinc naphthenate, triethylamine, triethylenediamine, 2-methyltriethyleneamine, dibutyl tin dilaurate; metal carboxylates, including, but not limited to: organobismuth catalysts such as bismuth neodecanoate, CAS 34364-26-6; zinc neodecanoate, CAS 27253-29-8; zirconium neodecanoate, CAS 39049-04-2; and zinc 2-ethylhexanoate, CAS 136-53-8; sulfonic acids, including but not limited to dodecylbenzene sulfonic acid, CAS 27176-87-0; and methane sulfonic acid, CAS 75-75-2; amino or organo-base catalysts, including, but not limited to: 1,2-dimethylimidazole, CAS 1739-84-0; and diazabicyclo[2.2.2]octane, CAS 280-57-9; and triphenyl phosphine; alkoxides of zirconium and titanium, including, but not limited to zirconium butoxide, (tetrabutyl zirconate) CAS 1071-76-7; and titanium butoxide, (tetrabutyl titanate) CAS 5593-70-4; and ionic liquid phosphonium, imidazolium, and pyridinium salts, such as, but not limited to, trihexyl(tetradecyl)phosphonium hexafluorophosphate, CAS No. 374683-44-0; 1-butyl-3-methylimidazolium acetate, CAS No. 284049-75-8; and N-butyl-4-methylpyridinium chloride, CAS No. 125652-55-3; and tetradecyl(trihexyl)phosphonium; and

wherein said Gamma Oligomer is an epoxy diacrylate.

2. A process for coating an optical fiber, the process comprising:

a) operating a glass drawing tower to produce a glass optical fiber; and

b) coating said glass optical fiber with a commercially available radiation curable Primary Coating composition;

c) optionally contacting said radiation curable Primary Coating composition with radiation to cure the coating;

d) coating said glass optical fiber with the radiation curable Secondary Coating composition of claim 1;

e) contacting said radiation curable Secondary Coating composition with radiation to cure the coating.

3. The process of claim 2 wherein said glass drawing tower is operated at a line speed of between about 750 meters/minute and about 2100 meters/minute.

4. A wire coated with a first and second layer, wherein the first layer is a cured radiation curable Primary Coating that is in contact with the outer surface of the wire and the second layer is a cured radiation curable Secondary Coating of claim 1 in contact with the outer surface of the Primary Coating,

wherein the cured Secondary Coating on the wire has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity: wherein the cured Secondary Coating on the wire has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:

A) a % RAU of from about 80% to about 98%;

B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and

C) a Tube Tg, of from about 50° C. to about 80° C.

5. An optical fiber coated with a first and second layer, wherein the first layer is a cured commercially available radiation curable Primary Coating that is in contact with the outer surface of the optical fiber and the second layer is a cured radiation curable Secondary Coating of claim 1 in contact with the outer surface of the Primary Coating,

wherein the cured Secondary Coating on the optical fiber has the following properties after initial cure and after one month aging at 85° C. and 85% relative humidity:

A) a % RAU of from about 80% to about 98%;

B) an in-situ modulus of between about 0.60 GPa and about 1.90 GPa; and

C) a Tube Tg, of from about 50° C. to about 80° C.